Post on 25-Jan-2017
UNIVERSITI TEKNIKAL MALAYSIA MELAKA
ERGONOMIC DEVELOPMENT OF SHOE SOLE DESIGN
This report submitted in accordance with requirement of the Universiti Teknikal
Malaysia Melaka (UTeM) for the Bachelor Degree of Manufacturing Engineering
(Manufacturing Design)
by
NUR SYUHADA BINTI HASIMUDDIN
B050910133
900120045144
FACULTY OF MANUFACTURING ENGINEERING
2013
UNIVERSITI TEKNIKAL MALAYSIA MELAKA
BORANG PENGESAHAN STATUS LAPORAN PROJEK SARJANA MUDA
TAJUK: Ergonomic Development of Shoe Sole Design
SESI PENGAJIAN: 2012/13 Semester 2
Saya NUR SYUHADA BINTI HASIMUDDIN
mengaku membenarkan Laporan PSM ini disimpan di Perpustakaan Universiti
Teknikal Malaysia Melaka (UTeM) dengan syarat-syarat kegunaan seperti berikut:
1. Laporan PSM adalah hak milik Universiti Teknikal Malaysia Melaka dan penulis. 2. Perpustakaan Universiti Teknikal Malaysia Melaka dibenarkan membuat salinan
untuk tujuan pengajian sahaja dengan izin penulis. 3. Perpustakaan dibenarkan membuat salinan laporan PSM ini sebagai bahan
pertukaran antara institusi pengajian tinggi.
4. **Sila tandakan ( )
SULIT
TERHAD
TIDAK TERHAD
(Mengandungi maklumat yang berdarjah keselamatan
atau kepentingan Malaysia sebagaimana yang termaktub
dalam AKTA RAHSIA RASMI 1972)
(Mengandungi maklumat TERHAD yang telah ditentukan
oleh organisasi/badan di mana penyelidikan dijalankan)
Alamat Tetap:
431-2 KM4
BUKIT PIATU
75150 MELAKA
Tarikh: ________________________
Disahkan oleh:
Cop Rasmi:
Tarikh:________________________
** Jika Laporan PSM ini SULIT atau TERHAD, sila lampirkan surat daripada pihak
berkuasa/organisasi berkenaan dengan menyatakan sekali sebab dan tempoh laporan PSM ini
perlu dikelaskan sebagai SULIT atau TERHAD.
DECLARATION
I hereby, declare this thesis entitled
“ERGONOMIC DEVELOPMENT OF SHOE SOLE DESIGN”
is the result of my own research except as cited in the reference.
Signature : ...............................................
Author’s Name : NUR SYUHADA BINTI HASIMUDDIN
Date : JUNE 2013
APPROVAL
This report is submitted to the Faculty of Manufacturing Engineering of UTeM as a
partial of the requirements for the degree of Bachelor of Manufacturing Engineering
(Manufacturing Design). The member of the supervisory committee is as follow:
Signature : ......................................................
Supervisor : MISS-MASNI AZIAN BINTI AKIAH
Date : JUNE 2013
i
ABSTRAK
Pilihan kasut sukan yang betul adalah penting untuk aktiviti-aktiviti yang berkaitan
dengan sukan bagi memastikan prestasi olahraga bertambah baik. Masalah yang
selalu berlaku adalah data ukuran kaki tidak mencukupi untuk penduduk dan
kecederaan yang berlaku di kalangan atlet Malaysia. Oleh sebab itu, terdapat
keperluan di dalam mempertimbangkan keperluan reka bentuk untuk sukan yang
berbeza dan profil kaki yang berbeza. Objektif pembelajaran ini adalah untuk
mendapatkan data antropometri untuk profil kaki pelajar UTeM, bagi
membangunkan reka bentuk ergonomik tapak kasut untuk pelajar UTeM dan untuk
menganalisis daya tekanan reka bentuk tapak kasut untuk ahli sukan UTeM. Skop di
dalam kajian ini ialah mengumpul data antropometri menggunakan ukuran grafik
visual. Berdasarkan data antropometri, reka bentuk dalam tapak kasut telah
dilakukan pada tiga profil kaki normal, kaki lengkungan tinggi dan kaki rata.
Kemudian, analisis daya tekanan dan anjakan telah dilakukan bagi membandingkan
bahan, getah dengan ethylene vinyl acetate (EVA) dan tiga jenis profil kaki. Kajian
ini mendapati, tapak kasut flat mencatatkan maksimum stress yang tertinggi
(28,1301 MPa) dan displacement (664,639 mm) untuk menjalankan aktiviti-aktiviti
sukan manakala bagi aktiviti sukan bola sepak, maksimum stress tertinggi tapak
kasut lengkungan tinggi (572,294 MPa ) dan maksimum displacement adalah tapak
kasut normal (49.413,8 mm). Analisis juga mendapati bahawa, bahan getah
mengakibatkan stress yang lebih rendah (27,889 MPa) dan maksimum displacement
yang lebih besar (379,141 mm) berbanding dengan Ethylene Vinyl Acetate (EVA)
material (28,077 MPa, 96,7997 mm). Kepentingan kajian ini adalah data
antropometri kaki akan menjadi berguna untuk pengilang kasut untuk
membangunkan reka bentuk kasut mereka untuk atlet Malaysia. Selain itu, reka
bentuk baru tapak kasut dalam yang berguna untuk prestasi sukan yang lebih baik
serta mengurangkan kecederaan kaki akibat aktiviti sukan.
ii
ABSTRACT
Proper selection of athletic shoes is important for sports related activities to ensure
improved athletic performance. The problem that always happened is inadequate data
foot measurement for Malaysian population and injuries happened among the
athletes. Therefore, there is the need to consider the design requirement for different
sports and different foot profile. The objectives of this study are to obtain the
anthropometry data of feet profiles for UTeM students, to develop an ergonomic
design of shoe sole for UTeM students and to analyse the contact stress of the shoe
sole design for UTeM sportsmen. The scope incorporated in this study is collecting
anthropometry data using visual graphic measurement. Based on the anthropometry
data, the design of inner shoe sole has been done for three foot profile which is
normal, high- arch and flat foot print. Then, the analysis of stress distribution and
displacement is done in comparing the material, rubber versus ethylene vinyl acetate
(EVA) and three type of foot profile. This study found that, flat inner shoe sole
recorded the highest maximum stress distribution (28.1301 MPa) and displacement
(664.639 mm) for running sports activities whereas for soccer sports activities, the
highest maximum stress distribution is high-arch inner shoe sole (572.294 MPa) and
maximum displacement is normal inner shoe sole (49413.8 mm). The analysis also
found that, rubber material resulted to lower stress distribution (27.889 MPa) and
greater maximum displacement (379.141 mm) compared to ethylene vinyl acetate
(EVA) material (28.077 MPa, 96.7997 mm). The significance of this study is the
anthropometry data of foot will be useful for shoe manufacturers to develop their
shoe design for Malaysian athletes. Besides that, the new designs of inner shoe sole
are useful for an improved athletic performance as well as reduce injuries of foot due
to sports activities.
iii
DEDICATION
To my beloved parents and family members who really give me support and love
that I really need to accomplish in this project study.
iv
ACKNOWLEDGEMENT
I would like to offer my deepest gratitude to my supervisor, Miss Masni-Azian Binti
Akiah from the bottom of my heart for all the support, encouragement and
inspirations manage to obtain all the way through of this project study. The working
relationship between my supervisor and me has provided a lot of knowledge and
experience. The help from my supervisor is priceless for me. Last and not least, my
highest thankfulness is dedicated to my beloved family members, friends and other
parties whom helped me directly or indirectly.
Thank you.
v
TABLE OF CONTENT
Abstrak i
Abstract ii
Dedication iii
Acknowledgement iv
Table of Content v
List of Tables vii
List of Figures viii
List of Abbreviations, Symbols and Nomenclatures xii
CHAPTER 1: INTRODUCTION 1
1.1 Project Background 1
1.2 Problem Statement 2
1.3 Objectives 2
1.4 Scope of Study 3
CHAPTER 2: LITERATURE REVIEW 4
2.1 Injuries Related to Foot during Sports Activities 4
2.2 Sports Shoe Designs Consideration 5
2.3 Ergonomic in Shoe Design 10
CHAPTER 3: METHODOLOGY 12
3.1 Introduction 12
3.2 Literature Search 12
3.3 Preliminary Testing 14
3.3.1 Direct Foot Scanning 14
3.3.2 Indirect Foot Scanning using Modelling Clay 15
3.3.3 Visual Graphic measurement 17
3.4 Anthropometry Data Collection 19
3.5 Design of Shoe Sole 19
3.6 Conduct Stress Analysis 20
vi
3.7 Data Analysis 21
CHAPTER 4: PRELIMINARY RESULT 22
4.1 Anthropometry Data of Foot 22
4.2 Design of Inner Shoe Sole for sports Use 26
4.3 Analysis of Inner Shoe Sole 29
4.3.1 Running Inner Shoe Sole 29
4.3.1.1 Maximum Stress of Running Inner Shoe Sole 30
4.3.1.2 Maximum Displacement of Running Inner
Shoe Sole 36
4.3.2 Soccer Inner Shoe Sole 41
4.3.2.1 Maximum Stress of Soccer Inner Shoe Sole 30 42
4.3.2.2 Maximum Displacement of Soccer Inner
Shoe Sole 48
4.3.3 Summary of Analysis 54
CHAPTER 5: CONCLUSION 55
5.1 Conclusion 55
5.2 Recommendation 56
REFERENCES 57
APPENDICES
A Gantt chart of FYP I and FYP II
B Consent Form and Questionnaire
C Anthropometry Data of Foot
vii
LIST OF TABLES
2.1 Specifically Shoe Fitting for Soccer and running Sports 9
2.2 Critical Requirement of Soccer and Running Sports 9
2.3 Anthropometric Data for Foot 11
4.1 Anthropometric Data of Male for Normal Foot Profile, n=16 23
4.2 Anthropometric Data of Male for High-arch Foot Profile, n=14 23
4.3 Anthropometric Data of Male for Flat Foot Profile, n=30 24
4.4 Anthropometric Data of Female for Normal Foot Profile, n=16 24
4.5 Anthropometric Data of Female for High-arch Foot Profile, n=14 25
4.6 Anthropometric Data of Female for Flat Foot Profile, n=30 25
viii
LIST OF FIGURES
2.1 Calluses on Foot Sole 5
2.2 Blister on Foot Sole 6
2.3 Moulded Studs of Soccer Shoe 4
2.4 Sole Structure 7
2.5 Rigid High Arch Foot, Normal Arch and Low Arch Flexible Foot 8
2.6 Example of Flexes at Toe-Off Shoe 8
3.1 Methodology Flow Chart 13
3.2 Spotcheck SKD-S2 Developer Cover the Foot 14
3.3 The Foot in 3D Cad using Direct Scanning 15
3.4 Foot Profile with Modelling Clay 15
3.5 Foot Profile covers with Spotcheck SKD-S2 Developer 15
3.6 Scanning Process 16
3.7 The Foot in 3D Cad using Indirect Scanning 16
3.8 The Glass Table 17
3.9 Foot’s Respondents on the Glass Table 17
3.10 The Foot in Visual Graphic Measurement 17
3.11 Side View of Foot Captured using Visual Graphic Measurement 17
3.12 Structure of Glass Table 18
3.13 Measurement of Foot using “Analyzing Digital Images” Software 18
3.14 Measure of Foot Length using Anthropometer 19
3.15 Measure of Foot Breadth using Anthropometer 19
3.16 Types of Foot Flat, Normal and High Arch 20
3.17 Force Distribution during Running Activity 20
3.18 Force Distribution during Soccer Activity 21
ix
4.1 Bottom of Foot Profile 22
4.2 Side of Foot Profile 22
4.3 Design of Three Types Inner Shoe Sole of Male for Normal,
High-arch and Flat 27
4.4 Design of Three Types Inner Shoe Sole of Female for Normal,
High-arch and Flat 28
4.5 Deformation Scale 29
4.6 Maximum Stress of Male Running Inner Shoe Sole 30
4.7 Rubber versus EVA for Male Normal Foot 31
4.8 Rubber versus EVA for Male High-arch Foot 31
4.9 Rubber versus EVA for Male Flat Foot 31
4.10 Normal, High-arch and Flat Inner Shoe Sole (Male) using
Rubber Material 32
4.11 Normal, High-arch and Flat Inner Shoe Sole (Male) using
EVA Material 32
4.12 Maximum Stress of Female Running Inner Shoe Sole 33
4.13 Rubber versus EVA for Female Normal Foot 34
4.14 Rubber versus EVA for Female High-arch Foot 34
4.15 Rubber versus EVA for Female Flat Foot 34
4.16 Normal, High-arch and Flat Inner Shoe Sole (Female) using
Rubber Material 35
4.17 Normal, High-arch and Flat Inner Shoe Sole (Female) using
EVA Material 35
4.18 Maximum Displacement of Male Running Inner Shoe Sole 36
4.19 Rubber versus EVA for Male Normal Foot 37
4.20 Rubber versus EVA for Male High-arch Foot 37
4.21 Rubber versus EVA for Male Flat Foot 37
4.22 Normal, High-arch and Flat Inner Shoe Sole (Male) using
Rubber Material 38
4.23 Normal, High-arch and Flat Inner Shoe Sole (Male) using
EVA Material 38
4.24 Maximum Displacement of Female Running Inner Shoe Sole 39
4.25 Rubber versus EVA for Female Normal Foot 39
x
4.26 Rubber versus EVA for Female High-arch Foot 40
4.27 Rubber versus EVA for Female Flat Foot 40
4.28 Normal, High-arch and Flat Inner Shoe Sole (Female) using
Rubber Material 41
4.29 Normal, High-arch and Flat Inner Shoe Sole (Female) using
EVA Material 41
4.30 Maximum Stress of Male Soccer Inner Shoe Sole 42
4.31 Rubber versus EVA for Male Normal Foot 43
4.32 Rubber versus EVA for Male High-arch Foot 43
4.33 Rubber versus EVA for Male Flat Foot 43
4.34 Normal, High-arch and Flat Inner Shoe Sole (Male) using
Rubber Material 44
4.35 Normal, High-arch and Flat Inner Shoe Sole (Male) using
EVA Material 44
4.36 Maximum Stress of Female Soccer Inner Shoe Sole 45
4.37 Rubber versus EVA for Female Normal Foot 46
4.38 Rubber versus EVA for Female High-arch Foot 46
4.39 Rubber versus EVA for Female Flat Foot 46
4.40 Normal, High-arch and Flat Inner Shoe Sole (Female) using
Rubber Material 47
4.41 Normal, High-arch and Flat Inner Shoe Sole (Female) using
EVA Material 47
4.42 Maximum Displacement of Male Soccer Inner Shoe Sole 48
4.43 Rubber versus EVA for Male Normal Foot 49
4.44 Rubber versus EVA for Male High-arch Foot 49
4.45 Rubber versus EVA for Male Flat Foot 49
4.46 Normal, High-arch and Flat Inner Shoe Sole (Male) using
Rubber Material 50
4.47 Normal, High-arch and Flat Inner Shoe Sole (Male) using
EVA Material 50
4.48 Maximum Displacement of Female Soccer Inner Shoe Sole 51
4.49 Rubber versus EVA for Female Normal Foot 52
4.50 Rubber versus EVA for Female High-arch Foot 52
xi
4.51 Rubber versus EVA for Female Flat Foot 52
4.52 Normal, High-arch and Flat Inner Shoe Sole (Female) using
Rubber Material 53
4.53 Normal, High-arch and Flat Inner Shoe Sole (Female) using
EVA Material 53
xii
LIST OF ABBREVIATIONS, SYMBOLS AND
NOMENCLATURE
% - Percent
3D - Three Dimensional
NG - Not Good
FYP - Final Year Project
PSM - Projek Sarjana Muda
EVA - Ethylene Vinyl Acetate
1
CHAPTER 1
INTRODUCTION
1.1 Project Background
Proper selection of athletic shoes is important for sports related activities to ensure
improved athletic performance. Good structural designs of athletic shoes are able to
provide adequate support to the foot and prevent musculoskeletal injuries. The
design of the shoe soles itself should be able to reduce stress and impact exerted onto
the feet due to different sports activities. Repeated or continuous contact between the
feet with the shoes will result to varying contact stress. Thus, different sports activity
will exhibit different stress effect.
One of the main components of an ergonomic athletic shoe would be the shoe sole
design. The design shall consider the anthropometry measurement for the selected
population. This study will focus on the design and development of shoe sole for
Malaysian sportsmen. The anthropometry data of feet for UTeM students is needed
for this study as the design guidelines for the shoe sole. The anthropometric
measures are usually expressed in 5th
, 50th
, and 95th
percentile measures. Gender and
genetics influences the anthropometric measurement. Generally, the anthropometric
measurements for men are larger than woman. On the other hand, genetics
differences can be shown from the varying measurements between populations at
different regions such as Europe and Asian populations. Current foot anthropometry
data is not adequate for Malaysian population. Therefore, there is a need for the
anthropometry data to be collected for the shoe sole design.
2
The anthropometry data collected in this study will be useful for shoe manufacturers
to develop their shoe design for the Malaysian athletes. Further stress analysis can be
simulated based on these data and the new designs are useful for an improved
athletic performance as well as reduce injuries of foot due to sports activities.
1.2 Problem Statement
The problem that always happened in this shoe sole design is the inadequate data of
foot measurement for Malaysian population. Inaccurate selection of shoes size will
cause the foot to be injured. Among the foot related injuries due to inappropriate use
of shoes will are blisters on the foot, calluses on the sole and ankle sprains (Saluta &
Nunley, 2010; Dexter, 2004). Furthermore, inappropriate selection of shoe size will
result to lack of stability and reduced athletic performance of the user. Other than
that, it may also cause musculoskeletal disorder among the user which will affect the
overall posture and performance of the athletes. In addition, different sports activities
will cause different stress distribution with varying impact on the foot profile.
Therefore, there is the need to consider different design requirement due to different
foot profile such as flat, normal and high arched foot.
1.3 Objectives
Based from the problems highlighted above, the objectives of this study are:
(a) To obtain the anthropometry data of feet profiles for UTeM students.
(b) To develop an ergonomic design of inner shoe sole for UTeM students.
(c) To analyse the contact stress of inner shoe sole design for UTeM sportsmen.
3
1.4 Scope of Study
The scopes that are covered in this study are as below:
(a) The anthropometry data of feet collected focuses on UTeM students’ adult age
18 to 30 years old.
(b) The inner shoe sole design and analysis focuses on running and soccer sports.
4
CHAPTER 2
LITERATURE REVIEW
2.1 Injuries Related to Foot during Sports Activities
Traumatic injuries frequently occur at foot and ankle in most sports activities. From
the research in multispecialty sports clinic, 25% of 12,681 injuries are involving to
foot and ankle during sports activities (Saluta & Nunley, 2010). According to Young
et.al (2005), the foot and ankle are important as the main interface between the
ground and body during walking and they are required to absorb impact loading
forces, give efficient propulsion and adapt with the segregated ground which is
consists 26 main bones in other to accomplish this task.
Soccer is the most popular sport in the world wide (Braver et.al, 2003). In addition,
the most commonly injuries happened in soccer sports are ankle sprains (Manning
et.al, 2006). The football player is also usually had their injuries related to mid-foot
or Lisfranc sprains by a sudden rotation of a planted foot or an axial load on a plantar
flexed foot (Saluta & Nunley, 2010).
The runners have high rates of running injuries between 30% and 75% per year for a
distance running (Daoud et.al, 2012). According to Shorten & Ph (2000), runner
experiences approximately 25,000 impacts of the ground during marathon. The
repeated impact loading of the runner’s body causes overuse injury. The impact also
causes rapid joint motion, soft tissue stresses and high muscle forces.
5
On the other hand, the runners are exposed to stress fracture due to high repetition
and low impact activities. These are caused by poorly cushioned shoes and stiff
running surfaces (Saluta & Nunley, 2010).
Apart from that, calluses can form on soles of feet and palm as shown in Figure 2.1.
Calluses at foot sole commonly form on the weight bearing areas and when it
becomes too thick, it will cause discomfort to the individual. Apart from that, blisters
also can form and occur on the soles because of the repeated friction as shown in
Figure 2.2 which commonly happened when wearing a new pair of shoes (Dexter,
2004). Thus, the callus and blisters formation on the foot sole can be minimised with
properly fitted shoes.
2.2 Sports Shoe Designs Consideration
For the soccer shoes, cleats provide an important role to give support in mid foot area
and traction to the feet during playing. The cleats can give increased speed and
manoeuvrability. The design for soccer cleat is important according to weather
conditions, field types and skill levels (Caselli, 2006).
Figure 2.1.: Calluses on Foot Sole
(Dexter, 2004)
Figure 2.2: Blister on Foot Sole
(Dexter, 2004)
6
As stated by Logan et al. (2010), fixation rotation can be reduced through design
consideration of shoe cleats. It is proposed that height of cleat were to be minimized
while maximizing the number of cleats and its diameter. Furthermore, the moulded
rubber cleats as shown in Figure 2.3 are usually designed for shoes which are
suitable for harder turf surface for better spring and traction effect. In addition, the
number, shapes and placement of the studs on the bottom of cleats are also an
important consideration in shoe design (Ozer & Barut, 2012). Thus, consider the
athlete of foot types can reduce the frequency of injury and provide an improved
performance.
Figure 2.3: Moulded Studs of Soccer Shoe (Caselli, 2006)
As stated by Caselli (2006), the runners will spend 800 times per mile during running
and the force will be three times the weight of runner’s body. There are five critical
components that should be considered which are the last, outer sole, heel counter,
midsole and upper. However, the scope of this project will focus more on the
midsole and outer sole.
Current trends with athletic shoe design focuses on fitting of the shoe and force
generation for an individual during sports activities. Generally, three characteristics
are involved which is stability, cushioning and guidance. The sole provide
cushioning and stability between the foot with the ground and plantar surface
(Hilgers et al., 2009). It involves three component which is anterior sole, mid sole
and outer sole. Lastly, there are design for straight, half bend or full bend. Those
designs provide more comfort to the athletes during intense sports activities.
7
In addition, the important requirements for sport shoes including the design,
cushioning, stability, grip, fitting, flexibility, weight, durability and air permeability.
The mid sole and outer sole are commonly made of ethylene vinyl acetate (EVA)
foam and rubber. From Figure 2.4, mid sole is categorized in three areas which are
fore foot (zone 1 to 9), mid foot (zone 10) and rear foot (zone 11) (Shimoyama et al.,
2010).
Figure 2.4: Sole Structure (Shimoyama et al., 2010)
According to Langone (2010), there are three classic types of foot profile which is,
normal arch, rigid high arch foot and low arch flexible foot (Figure 2.5). The contact
surface between different foot profiles can be measured using the wet paper test. The
test exhibit minimal contact for high arch foot, moderate contact for normal arch and
full contact for low arch. Thus, for improved performance, athletes with high arch
foot prefer the cushioned shoes, normal arch may use stable shoes and low arch shall
for more stable shoes than normal arch.
8
Figure 2.5: Rigid High Arch Foot, Normal Arch and Low Arch Flexible Foot
(Source: < http://www.edgeandwax.co.uk > 08 December 2012)
Harder soles offer less cushioning, wear longer and will be heavier (Caselli, 2006).
For the soft soles, it wears out faster but provide more cushioning and have lighter
weight. On the other hand, the midsole is also important because it can absorb shock,
provide stability and flexes at toe-off as shown in Figure 2.6. Gel air, bags and other
materials are used to increase the cushioning. However, when exposed to cold
temperature, the material will lose its cushioning ability. Thus, running shoe can take
consideration in cushioning, stability and motion control (Caselli, 2006).
Figure 2.6: Example of Flexes at Toe-Off Shoe
(Source: < http://www.powerfootwear.com/athletic-footwear > 05 December 2012)